US8397418B2 - System for providing electrical power to accessories mounted on the powered - Google Patents

Abstract

A firearm may have a plurality of power-consuming accessories that can be attached to the weapon. In order to reduce the weight of these power-consuming accessories, as well as the proliferation of their batteries, the Weapon Accessory Power Distribution System provides a common power source to power the power-consuming accessories attached to the weapon. One or more powered rails are provided to provide a point of electrical interconnection for the power-consuming accessories, absent the use of connectors with their tethering cables, which are susceptible to entanglement. The powered rail(s) are electrically interconnected with a power source, which typically is a battery mounted in the butt stock of the weapon.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation-in-part of U.S. patent application Ser. No. 12/791,460 filed on Jun. 1, 2010, titled “Rugged Low Light Reflectivity Electrical Contact,” which claims the benefit of U.S. Provisional patent application Ser. No. 61/183,250 filed on Jun. 2, 2009, titled “Non-Reflective, Conductive Mesh, Environmentally Robust Electrical Contacts.” This application is also a continuation-in-part of U.S. patent application Ser. No. 12/689,439 filed on Jan. 19, 2010, titled “Rifle Accessory Rail, Communication, And Power Transfer System—Power Distribution,” which claims the benefit of U.S. Provisional patent application Ser. No. 61/145,228 filed on Jan. 16, 2009; U.S. patent application Ser. No. 12/689,430 filed on Jan. 19, 2010, titled “Rifle Accessory Rail, Communication, And Power Transfer System,” which claims the benefit of U.S. Provisional patent application Ser. No. 61/145,232 filed on Jan. 16, 2009; U.S. patent application Ser. No. 12/689,436 filed on Jan. 19, 2010, titled “Accessory Mount For Rifle Accessory Rail, Communication, And Power Transfer System—Accessory Attachment,” which claims the benefit of U.S. Provisional patent application Ser. No. 61/145,216 filed on Jan. 16, 2009; U.S. patent application Ser. No. 12/689,437 filed on Jan. 19, 2010, titled “Rifle Accessory Rail, Communication, And Power Transfer System—Communication,” which claims the benefit of U.S. Provisional patent application Ser. No. 61/145,248 filed on Jan. 16, 2009; U.S. patent application Ser. No. 12/689,438 filed on Jan. 19, 2010, titled “Rifle Accessory Rail, Communication, And Power Transfer System—Battery Pack,” which claims the benefit of U.S. Provisional patent application Ser. No. 61/145,211 filed on Jan. 16, 2009; and U.S. patent application Ser. No. 12/689,440 filed on Jan. 19, 2010, titled “Rifle Accessory Rail, Communication, And Power Transfer System—Rail Contacts,” which claims the benefit of U.S. Provisional patent application Ser. No. 61/145,222 filed on Jan. 16, 2009. This application also is related to the US patent application titled “Communication And Control Of Accessories Mounted On The Powered Rail Of A Weapon” and the US patent application titled “Rail Contacts For Accessories Mounted On The Powered Rail Of A Weapon,” both of which are filed concurrently herewith. The foregoing applications are hereby incorporated by reference to the same extent as though fully disclosed herein.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

This application is sponsored by the US Department of Defense under Contract Numbers W15QKN-08-C-0072 and W15QKN-09-C-0045.

FIELD OF THE INVENTION

The invention relates generally to the field of electrical power distribution and, more particularly, to a system for providing electric power to power-consuming accessories which are mounted on a powered rail of a weapon.

BACKGROUND OF THE INVENTION

It is a problem to reliably provide electric power to power-consuming accessories which are mounted on a weapon in an environmentally hostile environment. The typical adverse natural environment includes, but is not limited to, corrosion, chemical contamination, extreme temperatures, humidity, rain, dirt, ice, and abrasion. The traditional approach is to have each power-consuming accessory completely self-contained, each with its own batteries. However, the weight of the batteries in all of the power-consuming accessories creates an imbalance in the weapon and adds a significant amount of weight to the weapon. That, coupled with the cost of provisioning numerous types of batteries renders self-contained accessories a poor choice.

Therefore, the provision of a common power source is a preferred solution. The Powered Rail must have a method of electrically connecting the power-consuming accessory to a common power source which is operationally associated with the weapon. The implementation of a common power source must be done in a manner to maintain balance of the weapon for ease of use and also simplicity of re-provisioning the batteries in the common power source. In addition, there must be a mechanism to enable the user to control the delivery of power to the power-consuming accessories.

BRIEF SUMMARY OF THE INVENTION

The above-described problems are solved and a technical advance achieved by the present System For Providing Electrical Power To Accessories Mounted On The Powered Rail Of A Weapon (termed “Weapon Accessory Power Source” herein) which is adapted for use in weapons, such as military weapons. A firearm used in military applications may have a plurality of accessories that can be attached to the weapon, with each accessory having a need for electric power. In order to reduce the weight of these power-consuming accessories, as well as the proliferation of batteries used to power these power-consuming accessories, a common power source is used to power whatever power-consuming accessory is attached to the weapon. A Weapon Accessory Power Distribution System provides one or more powered rails to provide a point of mechanical and electrical interconnection for the power-consuming accessories to provide quick connect mounting and dismounting of the power-consuming accessory, absent the use of connectors with their tethering cables, which are susceptible to entanglement. The powered rail(s) are electrically interconnected with the present Weapon Accessory Power Source, which can be a battery mounted in the butt stock of the weapon, a pistol grip mounted power source, a powered rail mounted power source, or an external power source electrically connected to the powered rail. The power transfer between the power source and the powered rail uses a permanent power distribution system mounted on the weapon.

The Weapon Accessory Power Distribution System is designed for use in an unprotected manner where the components are exposed to harsh ambient environmental conditions. The Weapon Accessory Power Distribution System provides the following benefits:

• • Use of a single compact power source,
  • Significant reduction in the weight of the accessory/power source system,
  • By moving mass rearward, the time to bring the weapon to point is reduced, as well as the time needed to “stop” the muzzle when the target is acquired.
  • Compatibility with the existing Picatinny Rail for mounting accessories,
  • Performance reliability, and
  • Inexpensive to manufacture.

The primary components of this Weapon Accessory Power Distribution System, which is used as an application example, are:

• • Battery Pack,
  • Power Distribution System,
  • Handguard (optional),
  • Powered Rail, and
  • Power-Consuming Accessory Mounting.

The following description provides a disclosure of the Weapon Accessory Power Source in sufficient detail to understand the teachings and benefits of the Weapon Accessory Power Source, as used with the Weapon Accessory Power Distribution System, which is delimited by the appended claims.

BRIEF DESCRIPTION OF THE DRAWINGS

FIGS. 1A-1C are illustrations of the prior art Picatinny Rail mounted on a military style weapon, which is used to mount accessories to the weapon as is well known in the art;

FIGS. 2A and 2B are illustrations of the system architecture of a military style weapon equipped with a Weapon Accessory Power Distribution System;

FIGS. 3A and 3B are illustrations of a typical butt stock battery pack of the Weapon Accessory Power Source;

FIGS. 4A-4C are illustrations of the Power Distribution System which interconnects the Battery Pack to the Powered Rail in the Weapon Accessory Power Distribution System;

FIGS. 5A-5C are illustrations of the Handguard assembly, including the Powered Rail, of the Weapon Accessory Power Distribution System;

FIGS. 6A and 6B are plan and perspective views, respectively, of two implementations of the printed circuit board used to implement the Powered Rail, whileFIG. 6C is an exploded perspective view of the printed circuit board used to implement the Powered Rail;

FIGS. 7A and 7B illustrate the details of the Powered Rail electrical interconnection;

FIGS. 8A-8C are illustrations of the typical mechanical interconnection and electrical interconnection of a Power-Consuming Accessory to the Handguard and Powered Rail;

FIG. 9 is a schematic of loose mesh grid disks, plain side up and solder side up, which are used to implement the Low Reflectivity Contact;

FIG. 10 is an illustration of a Low Reflectivity Contact soldered to a Printed Circuit Board;

FIGS. 11A and 11B are illustrations of the light reflectivity geometry of the Low Reflectivity Contact;

FIGS. 12A-12I are illustrations of details of the butt stock version of the Weapon Accessory Power Source;

FIGS. 13A and 13B are illustrations of details of the pistol grip version of the Weapon Accessory Power Source;

FIGS. 14A-14C are illustrations of details of the powered rail version of the Weapon Accessory Power Source; and

FIGS. 15A and 15B illustrate details of the external version of the Weapon Accessory Power Source.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

Definitions

Contact—One-half of a Contact Pair consisting of an electrically conductive surface which is electrically connected to a power source or power-consuming device.

Contact Pair—A set of two Contacts which, when brought together in mechanical contact, complete an electrical circuit enabling the transfer of electrical power and/or electrical signals therebetween.

Visible Spectrum—The visible spectrum is the portion of the electromagnetic spectrum that is visible to (can be detected by) the human eye. Electromagnetic radiation in this range of wavelengths is called “visible light” or simply “light”. A typical human eye responds to wavelengths from about 390 nm to 750 nm. In terms of frequency, this corresponds to a band in the vicinity of 400 THz to 790 THz.

Electrical Resistivity—Electrical Resistivity is a measure of how strongly a material opposes the flow of electric current. A low resistivity indicates a material that readily allows the movement of electrical charge.

Electrical Conductivity—Electrical Conductivity (the inverse of Electrical Resistivity) is a measure of how strongly a material supports the flow of electric current. A high conductivity indicates a material that readily allows the movement of electrical charge.

Picatinny Rail

It is well known to those skilled in the art that rapid fire firearms, utilized particularly in military operations, are characterized by the heating of the barrel of the weapon to relatively high temperatures. At such temperatures, the barrel cannot be held safely by the person firing the weapon. Consequently, a variety of handguards have been developed to shroud the barrel of such rapid fire weapons to enable the person firing the weapon to grip the forward portion of the weapon while mitigating the possibility of burning the hand of the person firing the weapon, yet also providing adequate cooling for the barrel of the weapon.

FIGS. 1A-1C are illustrations of the prior art Picatinny Rail mounted on amilitary style weapon1, which is used to mount accessories to the weapon as is well known in the art. Theweapon1 contains the standard components, such asreceiver2,grip3, barrel4,handguard5,6,butt stock7, andfront sight8. The Picatinny Rail or MIL-STD-1913 rail (and NATO equivalent—STANAG 4694) is a bracket used on some firearms to provide a standardized accessory mounting platform. Its name comes from the Picatinny Arsenal in New Jersey, USA where it was originally tested and was used to distinguish it from other rail standards at the time. The Picatinny Rail comprises a series of ridges with a T-shaped cross-section interspersed with flat “locking slots” (also termed “recoil groove”). Scopes are mounted either by sliding them on from one end of the Picatinny Rail or the other end of the Picatinny Rail by means of a “rail-grabber” which is clamped to the Picatinny Rail with bolts, thumbscrews, or levers, or onto the slots between the raised sections. Scopes and other accessories can also (and usually are) mounted from the sides of the rail, not just slid over the ends.

With particular reference toFIGS. 1A-1C, the Picatinny Rail is shown as integrated intohandguard5,6, which includes a top semi-cylindrical (C)part11 and a bottom semi-cylindrical (C)part12. The topsemi-cylindrical part11 is defined by a back end having a back end ledge that engages with a slip ring and a front end having a front end ledge that engages with the receptor cap to retain thepart11 about the barrel4. Similarly, thebottom part12 is defined by a back end having a back end ledge that engages with the slip ring and a front end having a front end ledge that engages with the receptor cap to retain thepart12 about the barrel4. Anaccessory adapter rail13 extends longitudinally and upwardly from the topsemi-cylindrical part11. Thehandguard5,6 may also include accessory adapter side rails and accessory adapter bottom rails. Thus, the Picatinny Rail is formed of a multi-faceted (F1-F4) structure, on each facet of which accessories can be mounted. Apertures A are provided along the length dimension L of the Picatinny Rail to enable the barrel4 of theweapon1 to be cooled by air circulation from the ambient environment.

The Picatinny Rail was originally designed for use with scopes. However, once established, the use of the Picatinny Rail was expanded to other accessories, such as tactical lights, laser aiming modules, night vision devices, reflex sights, fore grips, bipods, and bayonets. Because the Picatinny Rail was originally designed and used for telescopic sights, the rails were first used only on the receivers of larger caliber rifles. However, their use has extended to the point that Picatinny Rails and accessories have replaced iron sights in the design of many firearms, and they are also incorporated into the undersides of semi-automatic pistol frames and even on grips.

In order to provide a stable platform, the rail should not flex as the barrel heats and cools; this is the purpose of the locking slots: they give the rail considerable room to expand and contract lengthwise without distorting its shape.

Powering the multitude of accessories used on weapons equipped with the Picatinny Rail has been accomplished by equipping each accessory with its own set of batteries. A significant problem with this paradigm is that multiple types of batteries are used for accessories, thereby requiring an extensive inventory of replacements. In addition, the batteries, especially on high power accessories, add significant weight to the barrel end of the weapon, adding strain to the user of the weapon to hold the barrel “on target” in an “off-hand manner” without support for the barrel.

Reticle Illumination

One example of an accessory for a weapon is a scope which includes a reticle which can be illuminated for use in low light or daytime conditions. The reticle is a grid of fine lines in the focus of the scope, used for determining the position of the target. With any illuminated low light reticle, it is essential that its brightness can be adjusted. A reticle that is too bright causes glare in the operator's eye, interfering with his ability to see in low light conditions. This is because the pupil of the human eye closes quickly upon receiving any source of light. Most illuminated reticles provide adjustable brightness settings to adjust the reticle precisely to the ambient light. Illumination is usually provided by a battery powered LED, though other electric light sources can be used. The light is projected forward through the scope and reflects off the back surface of the reticle. Red is the most common color used, as it least impedes the shooter's night vision. This illumination method can be used to provide both daytime and low light conditions reticle illumination.

Other examples of powered accessories include, but are not limited to: tactical lights, laser aiming modules, and night vision devices.

Weapon Equipped With Weapon Accessory Power Distribution System

FIGS. 2A and 2B are illustrations of the system architecture of aweapon2 equipped with a Weapon Accessory Power Distribution System. The primary components of the basic Weapon Accessory Power Distribution System as noted above are:

• • Butt Stock21 with Battery Pack33 (shown inFIG. 3A);
  • Power Distribution System22;
  • Handguard23 (optional);
  • PoweredRail24; and
  • Powered Accessory Mounting25 (shown inFIG. 8A).

The existingweapon2 includes in well-known fashion anupper receiver101,lower receiver102,barrel103,muzzle104,grip105, andfront sight106. While a military-style weapon is described herein, the teachings of this application are equally applicable to other firearms, such as handguns, fixed-mount machine guns, as well as non-weapons based systems. The Weapon Accessory Power Distribution System is added to this standard military-style weapon2 as described herein.

TheHandguard23 performs the barrel shielding function as in the Picatinny Rail noted above, but has been modified, as shown inFIGS. 2A and 2B, to accommodate thePowered Rail24 and electrical interconnection of thePowered Accessory Mounting25 to thePowered Rail24, as described below. In particular, a combination ofPowered Rails24 andHandguard sections23 are attached together to form a structure which typically encircles thebarrel103. The Powered Rails24 in effect form facets around the periphery of the resultant Handguard structure. Thus, herein the term “Handguard” is used to represent the sections of a handguard structure as well as the well-known combination of Handguard sections and Powered Rails which encircle thebarrel103 as shown inFIGS. 2A and 2B. As alternative structures, thePowered Rail24 can be attached to aHandguard23 that encircles the barrel. Furthermore, there is no requirement to use theHandguard23 as an integral component of the Weapon Accessory Power Distribution System, so theHandguard23 can be optional, with the Powered Rail(s)24 being attached to the weapon in some other manner, such as anupper receiver rail101 inFIG. 2A. For the purpose of illustrating the Weapon Accessory Power Distribution System, the first of the above-listed configurations is used herein.

Handguard

As noted above, theHandguard23 was developed to shroud thebarrel103 of arapid fire weapon2 to enable the person firing theweapon2 to grip the forward portion of theweapon2 while mitigating the possibility of burning the hand of the person firing theweapon2, yet also providing adequate cooling for thebarrel103 of the weapon. Handguards find application in rifles, carbines, and fixed-mount weapons, such as machine guns. However, the Weapon Accessory Power Distribution System can also be used in modified form for handguns, as an accessory mounting platform and as an accessory power source.

FIGS. 5A-5C are perspective exploded view, side view, and end view illustrations, respectively, of theHandguard23 assembly, including the PoweredRail24, of the Weapon Accessory Power Distribution System. ThePowered Rail24, as shown as an example, includes a series of ridges with a T-shaped cross-section interspersed with flat “locking slots”. This version of theHandguard23, therefore, can be viewed as an adaptation of the existing non-powered Picatinny Rail which involves milling slots along the length of the mechanical accessory attachment points23R in the upper Handguard section (23U) and the lower Handguard section (23L) in order to install one or more power distribution Printed Circuit Boards60-1 to60-4, withFIG. 5C showing an end view of the slots formed in the various facets F1-F4 of theHandguard23. As with the Picatinny Rail, Apertures A are provided along the length dimension L of theHandguard23 to enable thebarrel103 of theweapon2 to be cooled by air circulation from the ambient environment. Other Powered Rail configurations are possible, and this architecture is provided as an illustration of the concepts of the Weapon Accessory Power Distribution System.

One or more of the Powered Rail subassemblies (typically Printed Circuit Boards)60-1 to60-4 can be inserted into the respective slots formed in the Powered Rail24 (on the corresponding facets F1-F4 of the Handguard23) thereby to enable power-consuming accessories to be attached to theHandguard23 of theweapon2 via thePowered Rail24 on any facet F1-F4 of theHandguard23 and to be powered by the corresponding Printed Circuit Board60-1 to60-4 installed in thePowered Rail24 on that facet.

Battery Pack

The Battery Pack can be implemented in a number of assemblies and mounted on various portions of the weapon (such as on the Powered Rail, or in a pistol grip, or in a remote power source, and the like) as described in the above-noted U.S. patent application Ser. No. 12/689,438 filed on Jan. 19, 2010, titled “Rifle Accessory Rail Communication And Power Transfer System—Battery Pack”. For the purpose of this description,FIGS. 3A and 3B are illustrations of atypical Butt Stock21 andBattery Pack33 of the Weapon Accessory Power Distribution System. For example, a butt stock/recoil tube battery pack assembly includes anadjustable butt stock21, acam latch32, and aremovable battery pack33. Thebutt stock21 adds a compartment to the underside of the existing lower receiver extension (also termed “buffer tube” herein)assembly34 which allows thebattery pack33 to be installed and withdrawn for removal through the rear of the rifle. Thebattery pack33 mounts on thebuffer tube assembly34 independent of thebutt stock21 which telescopes along the rifle. Thebutt stock21 is adjustable and can be extended in various multiple intermediate positions to provide an adjustable length of the firearm, as is well known in the art. By moving the mass of the battery rearward on the weapon, the time required to bring the weapon to point is reduced, as well as the time needed to “stop” the muzzle when the target is acquired.

Power Distribution System

ThePower Distribution System22 is shown inFIGS. 2A,2B, and4A-4C as a one-piece housing201 and ruggedizedpower rail connector202 where sealing integrity is maintained during exposure to adverse environmental conditions. Thepower rail connector202 consists of a metallic shell body,contact pin receptacle203, with a press fitmulti-finger spring contact204 assembled into thecontact pin receptacle203. Themulti-finger spring contact204 provides compliance to variations in the mating pin to ensure continuous current carrying capacity of the connection. Thecontact pin receptacle203 includes a solder tail portion for soldering cable wires. Thebottom panel insulator205 mounts thecontact pin receptacle203 with the bottom part and fitted over the connectorcontact pin receptacle203 and is sealed with a sealing compound. Afastener206 and retainingring207 are used to secure the connector assembly into the rail pin contacts.

An electric wire is routed from theBattery Pack33 in theButt Stock21 to thePowered Rail24. The external wiring is housed inside a durable and impactresistant polymer shroud108 that conforms to thelower receiver102. The shroud is securely retained by a quick connect/disconnect pivot andtakedown pin111 as well as the boltrelease roll pin109 in the trigger/hammer pins110. The shrouded power cable runs from theBattery Power Connector107 at theBattery Pack33 to thePower Rail Connector202. This design provides an easy access for replacing or repairing the cable assembly, eliminates snag hazards or interferences with the rifle operation and requires no modifications to the riflelower receiver102 housing.

Powered Rail

ThePowered Rail24 is used to electrically interconnect a power source (Battery Pack33) with the various accessories mounted on thePowered Rail24, such that thePowered Rail24 of theHandguard23 provides the mechanical support for the accessory and thePowered Rail24 also provides the electrical interconnection. In this example, thePowered Rail24 is attached to and coextensive with theHandguard23 sections, such that the mounting of a Power-Consuming Accessory on thePowered Rail24 results in simultaneous mechanical and electrical interconnection.

FIGS. 6A and 6B are top views of two versions of the printed circuit board used to implement thePowered Rail24;FIG. 6C is an exploded view of the printed circuit board used to implement thePowered Rail24;FIGS. 7A and 7B illustrate the details of thePowered Rail24 electrical interconnection; andFIGS. 8A-8C are illustrations of the typical mechanical interconnection and electrical interconnection of a Power-Consuming Accessory to theHandguard23 andPowered Rail24.

As noted above, thePowered Rail24 comprises one or more Printed Circuit Board Assemblies (60-1 to60-4) which are mounted in the apertures formed in a successive plurality of locking slots on the PoweredRails24 to carry power to power-consuming accessories which are mounted on thePowered Rail24 at various locations. The Printed Circuit Boards (60-1 to60-4) are soldered to electricallyconductive busses72,74. In addition, a conductive pin connector includes a terminal portion at one end which is pressed into the mating hole (not shown) in the interconnectelectrical bus72. Retaining clips71 are manufactured from resilient metallic spring material, which are anchored on theupper rail connector75 and a clamp hook feature of the retainingclip71 is used to securely hold thelower rail connector76 by engaging features formed on thelower rail connector76.FIG. 7B illustrates the retaining clips71 and electricallyconductive busses72 typically encapsulated in an insulative protective coating. The connector is removable and can be mounted easily through the retaining clips71 which provide positive retention and a means of securing the connector halves. Mated connector pairs have tab features which captivate the clips.

FIGS. 6A and 6B illustrate the architecture of the printed circuit board used to implement the PrintedCircuit Board62 where remote power is applied via thepositive connector contact61P and thenegative connector contact61N. As shown inFIG. 6A, the power is routed by the electrical traces on the PrintedCircuit Board62. The positive current frompositive connector contact61P is routed to the center of the Printed Circuit Board switch (for example,63-5) where it is switched via operation of the switch64 (shown inFIG. 6C) to contact63P-5, while the negative current from thenegative connector contact61N is routed to thenegative bus62N or negative bus contact pads (for example,62N3). The example shown in these figures provided thirteen positions where a power-consuming accessory can be attached and contact the power contacts of thePowered Rail24. In particular, on bothFIGS. 6A and 6B, there are thirteenpositive contacts62P-1 to62P-13 (only several of which are numbered on the figures to avoid clutter). InFIG. 6A, a continuousnegative bus62N is provided as the other power source connection. InFIG. 6B, the negative power source connections are provided by thirteen individual negativebus contact pads62N-1 to62N-13 (only several of which are numbered on the figures to avoid clutter). On the PrintedCircuit Board60A, there are points of attachment, typically comprisingnotches64A and64B, which are used to secure the printed circuit board in place in the corresponding slot of thePowered Rail24 via a pin clip arrangement.

The positive62P-3,62P-8 (for example) and negative62N-3,62N-8 contacts (onFIG. 6B) can be continuously powered, especially in the case where only one set of contacts is provided, or can be switch activated by metallic snap dome switches63-3,63-8 which are placed over positive common94 (as shown inFIG. 10) and are in electrical contact with the accessory positive switchedcontact62P-3,62P-8. The metallic snap dome switch has a pair of conductive contacts which are normally in the open mode; when the cover of the metallic snap dome switch is depressed via a projection on the exterior surface of the power-consuming accessory which is mounted on thePowered Rail24 juxtaposed to the metallic snap dome switch, these contacts mate and provide an electrical connection between positive common94 and a positive switchedcontact62P as shown inFIG. 10. The metallic snap dome switch is a well-known component and consists of a curved metallic dome that spans two conductors (positive common94 and a positive switchedcontact62P (as shown inFIG. 10) such that when the dome is depressed, it snaps downward to electrically bridge the two conductors. The accessory positive switchedcontact62P and the accessory common negativebus contact pad62N are both implemented using the Low Reflectivity Contact described below.

FIG. 6C illustrates an exploded view of the power distribution Printed Circuit Board assembly where anon-conductive layer65 prevents the metal weapon Rail from electrically shorting the power distribution PrintedCircuit Board62.Spacer layer63 is a non-conductive element which holds the snap dome switches in place so they do not move laterally during assembly. Metallic snap dome switches68 provide the electrical switching action to mounted rail accessories.Top cover layer65 provides environmental protection to the PrintedCircuit Board62 and the metallic snap dome switches64 when the aforementioned layers are assembled.

Powered Accessory Mounting

FIGS. 8A-8C are illustrations of the typical mechanical interconnection and electrical interconnection of a power-consuming accessory (such as flashlight8) to theHandguard23 andPowered Rail24. The perspective view ofFIG. 8A shows how thePowered Accessory Mounting25 attaches the power-consuming accessory to thePowered Rail24 and consists of arail grabber301,spring contacts302,spring plungers303, and face seals304. The spring plungers303 depress the snap-dome switches on thePowered Rail24, thespring contacts302 provide electrical contact with the fixedelectrical bus contacts62M and62P-* on thePowered Rail24 Printed Circuit Board assembly, and the face seals304 provide environmental protection.

FIGS. 8B and 8C are cutaway end views of the interconnection of a power-consuming accessory to theHandguard23 andPowered Rail24. In particular, the power-consuming accessory and associated Powered Accessory Mounting ACC are mechanically attached to theHandguard23 in well-known fashion (via screw clamp SC shown here). The Powered Accessory Mounting ACC includes a pair of spring contact pins82A,82B which contact correspondingLow Reflectivity Contacts62N and62P which are mounted on Printed Circuit Board60-3. Similarly, the Powered Accessory Mounting ACC includes aspring plunger303 which contacts corresponding metallicsnap dome switch64 which is mounted on Printed Circuit Board60-3.

Characteristics Of Electrical Contacts And Connectors

An ideal electrical connector has a low contact resistance and high insulation value. It is resistant to vibration, water, oil, and pressure. It is easily mated/unmated, unambiguously preserves the orientation of connected circuits, reliable, and carries one or multiple circuits. Desirable properties for a connector also include easy identification, compact size, rugged construction, durability (capable of many connect/disconnect cycles), rapid assembly, simple tooling, and low cost. No single electrical connector has all of the ideal properties. The proliferation of types of electrical connectors is a reflection of the differing importance placed on the design factors.

From a light reflectivity standpoint, the selection of low resistivity metals to construct the contact contradicts with the goal of achieving low light reflectivity. In particular, gold is highly conductive and makes an excellent choice for a contact, but has a high light reflectivity. If coatings are applied to a gold contact to reduce the light reflectivity, the resistivity of the contact is increased and the coatings quickly wear off in a hostile ambient environment where there are many connect/disconnect cycles. Mechanically modifying the surface of the gold to reduce the flat light reflecting plane presented to incoming visible light also reduces the conductivity of the contact and fails to achieve adequate reductions in light reflectivity reduction. Similar problems are encountered with attempts to alloy gold with other metals.

Characteristics Of The Low Reflectivity Contact

FIG. 9 is a schematic of loose mesh contact disks,plain side90 up andsolder side91 up, which are used to implement the Low Reflectivity Contact; andFIG. 10 is an illustration of aLow Reflectivity Contact92 soldered to a PrintedCircuit Board93. TheLow Reflectivity Contact92 consists of one Contact of a Contact Pair and is manufactured from a suitable material, with one example being a 400 mesh,alloy 304 Stainless Steel which is woven with a 0.001″ thick wire of cylindrical cross-section. The mesh is cut into the desired shape, such as a circle, and one side of the mesh is tinned with solder and soldered onto a Printed Circuit Board (PCB) which is designed to carry power from a power source to the electrical contacts. The other Contact of the Contact Pair consists of a spring loaded contact pin (or lever or any other mechanism to make mechanical contact with the Low Reflectivity Contact) to touch the mesh surface of the Low Reflectivity Contact to provide an electrical connection.

The selection of a wire mesh to implement the electrical contacts is dictated by the need to provide a low light reflectivity characteristic for the exposed electrical contacts. The need for low light reflectivity is important in certain applications, such as military weapons. In addition, the Low Reflectivity Contact provides a target of dimensions which enable the mating Contact of the Contact Pair to complete the circuit connection without the need for precise spatial three-dimensional alignments of the two Contacts of the Contact Pair.

FIGS. 11A and 11B are illustrations of the light reflectivity geometry of the Low Reflectivity Contact. The Low Reflectivity Contact typically comprises amesh grid1101 formed of a matrix ofelectrical wires1104 and1105 which are interconnected to form a matrix withapertures1103 formed in the surface thereof. Alternatively, themesh grid1101 can be formed of a sheet of electrically conductive material withapertures1103 formed in the surface thereof. Incident visible light1102 (as well as other wavelengths of light) is dispersed by theelectric wires1104,1105; and only a small fraction of the incident visible light passes through theapertures1103 of themesh grid1101 to theunderlying surface1106, which is typically a conductive pad on the surface of the Printed Circuit Board. The incident light1107 that passes through theapertures1103 is reflected1108 offsurface1106 and strikes the bottom surface of themesh grid1101. Therefore, the only way the incident visible light is retransmitted back out of the Low Reflectivity Contacts is for the reflectedbeam1108 to pass through anaperture1103. Thus, by the proper selection of the size of theelectric wires1104,1105, the density of the wires in the matrix, and the spacing between themesh grid1101 and theunderlying surface1106, the size of the apertures and the light reflection path can be managed to substantially eliminate the reflection of visible light off the Low Reflectivity Contact.

Thus, the Low Reflectivity Contact minimizes light reflectivity by the use of a conductive mesh grid which is attached to an underlying conductive surface. The conductive mesh grid comprises a substantially planar structure, typically a matrix of interconnected wires with apertures formed between the intersecting wires, and is used to form the outer surface of the electrical contact. The weave density, weave geometry, and wire diameter of the conductive mesh grid maximizes the attenuation of reflected light in the visible spectrum, yet maintains high electrical conductivity and a lack of sensitivity to contamination via the choice of materials used to implement the Low Reflectivity Contact.

Butt Stock Mounted Power Source

FIGS. 12A-12I are illustrations of details of the butt stock version of the Weapon Accessory Power Source. As shown inFIGS. 12A-12E, thebattery33 can be mounted on the bottom side of the buffer tube/receiver extension34 by the use of a dovetailslide guide rail1214 that extends longitudinally into the buffer tube/receiver extension34 and mates with the dovetail slide channel1215 (FIG. 12E) formed on the side of thebattery pack33. Thebattery pack33, when seated in the buffer tube/receiver extension34, has itspower connection1218 engage the mating electrical connection ofrifle power socket1216 thereby to provide power to thePowered Rail24 as shown inFIGS. 12F and 12I and as described herein.Detent balls1212, shown inFIG. 12C, operate withpivot pin1211 temporarily holding thecam lever1208 in a preset position extended away frombutt stock21 when thecam lever1208 is rotated onpivot pin1211 thereby to enable the installation of thebattery pack33 into buffer tube/receiver extension34. When thebattery pack33 is inserted into buffer tube/receiver extension34 andcam lever1208 is rotated onpivot pin1211 into the closed position,detent balls1212 provide a lock to prevent accidental release of thebattery33 from the buffer tube/receiver extension34.

Since thebattery33 is mounted in the buffer tube/receiver extension34, theadjustable butt stock21 can slide along the buffer tube/receiver extension34 and be set in any of a number of predetermined positions. In particular, theadjustable butt stock21 has both locking andquick release mechanisms1209, as shown inFIG. 12A, which provide the user with the ability to lock theadjustable butt stock21 on the buffer tube/receiver extension34 in any of a plurality of predetermined positions which thereby enables the user to adjust the overall length of theweapon2.Indexing notches1202 are provided on either side of aslide guide ramp1201, which extends along the length of the buffer tube/receiver extension34 and rides on a matingslide guide slot1207.Clevis pin1204A and the associated retainingring1206 is used to secure therelease lever1205 to thelatch arm1203 and thebutt stock21, while clevis pin1204B attachestorsion spring1219 to latcharm1203 to provide a spring force to holdlatch arm1203 away from the bottom side ofbutt stock21. Operation of therelease lever1205 compressestorsion spring1219 and causes thelatch arm1203 to rotate on clevispin1204A thereby to disengage thelatch arm1203 from the one ofindexing notches1202 in which it presently is seated, thereby enabling the user to slide theadjustable butt stock21 in the desired direction on the buffer tube/receiver extension34. Arelease stop tab1220 is provided to limit the travel of theadjustable butt stock21 on the buffer tube/receiver extension34. Release of therelease lever1205 causes thetorsion spring1219 to force thelatch arm1203 to rotate around clevis pin1204A in an upward direction into anindexing notch1202, thereby locking thebutt stock21 in position.

As shown inFIGS. 12G-12H, thebattery pack33 consists of a pair of exposed electrode terminals, positive1218P and negative1218N, as well as internalbattery spring terminals1223 which serve to engage one end of a plurality ofreplaceable battery cells1221. Aremovable battery cover1217 secures thebattery cells1221 in thebattery housing compartment1222. Theremovable battery cover1217 consists of thecover plate1217P,spring terminals1223,rubber washer bumpers1224, O-ring gaskets1228, and acover screw mechanism1225 which opens and closes the battery compartment. Thecover screw mechanism1225 includes a threaded screw which extends through thebattery cover1217 and a threadedlocking nut1227 having an internal mount feature on thebattery housing1221.

Alternative power source configurations include the use of abattery pack1302 attached to the bottom of thepistol grip105 as shown inFIG. 13B. Another power source configuration is to mount thebattery pack1301 in the fore-grip105 as shown inFIG. 13A. Thebattery pack1301 can be designed to fit into a mount that replaces the lower fore-grip105. An additional method, illustrated inFIGS. 14A-14C, entails mounting the battery pack1401-1403 directly to thehandguard23 where it electrically connects to the associatedPowered Rail24, where the battery pack1401-1403 delivers power to thePowered Rail24 through the contacts as described above. Connection to thePowered Rail24 can also be used, as shown inFIGS. 15A and 15B, to tether abattery pack1502 which is located external to theweapon2 via acable1501. Thesoldier1500 carries thebattery pack1502 as part of their equipment, which includesradio1504 andcommunication microphone1503. This last configuration can also be used to provide a recharging capability to the battery pack, wherever mounted, where thePowered Rail24 is used as an interface to a recharging system.

SUMMARY

There has been described a Weapon Accessory Power Source. It should be understood that the particular embodiments shown in the drawings and described within this specification are for purposes of example and should not be construed to limit the invention, which is described in the claims below. Further, it is evident that those skilled in the art may make numerous uses and modifications of the specific embodiment described without departing from the inventive concepts. Equivalent structures and processes may be substituted for the various structures and processes described; the sub-processes of the inventive method may, in some instances, be performed in a different order; or a variety of different materials and elements may be used. Consequently, the invention is to be construed as embracing each and every novel feature and novel combination of features present in and/or possessed by the apparatus and methods described.

Claims (17)

1. A Weapon Accessory Power Distribution System for providing a supply of electrical power for use by at least one power-consuming accessory operatively associated with a weapon, said weapon power distribution system comprising:

a handguard, which extends along a length of a barrel of a weapon and which mechanically supports one or more power-consuming accessories;

a receiver extension attached at a distal end of a receiver of a weapon and containing a mechanical feature formed along a length thereof;

a power source mounted on said receiver extension by the interconnection of a mechanical feature on the power source with the mechanical feature of the receiver extension, comprising:

a housing,

a pair of exposed electrode terminals mounted on an exterior surface of said housing,

a plurality of replaceable battery cells housed in said housing and electrically connected to said electrode terminals, and

wherein said power source has formed on said housing a dovetail slide guide rail that mates with a dovetail slide channel formed on said receiver extension;

an adjustable buttstock containing an aperture formed along a length thereof which aperture encloses the receiver extension and the attached power source and which provides a slideable attachment of said adjustable buttstock to said receiver extension for positioning said adjustable buttstock at one of a plurality of predetermined positions on said receiver extension;

a powered rail, incorporated in said handguard and extending along at least a portion of a length of a barrel of said weapon and connected to said power source, for providing a source of electrical power to a one or more power-consuming accessories which are mechanically and electrically attached to the powered rail; and

a power distribution system for electrically interconnecting said power source and said powered rail.

2. The Weapon Accessory Power Distribution System ofclaim 1 wherein said power source further comprises:

internal battery spring terminals which serve to engage one end of a plurality of replaceable battery cells and are electrically connected to said electrode terminals.

3. A Weapon Accessory Power Distribution System for providing a supply of electrical power for use by one or more power-consuming accessories operatively associated with a weapon, comprising:

a handguard, which extends along a length of a barrel of a weapon and which mechanically supports one or more power-consuming accessories;

a receiver extension attached at a distal end of a receiver of a weapon and containing a mechanical feature formed along a length thereof;

an adjustable buttstock containing an aperture formed along a length thereof which aperture encloses the receiver extension and an attached power source and which provides a slideable attachment of said adjustable buttstock to said receiver extension for positioning said adjustable buttstock at one of a plurality of predetermined positions on said receiver extension;

wherein said power source comprises:

a housing,

a pair of exposed electrode terminals mounted on the exterior surface of said housing,

a plurality of replaceable battery cells housed in said housing electrically connected to said electrode terminals, and

wherein said power source has formed on said housing a dovetail slide guide rail that mates with a dovetail slide channel formed on said receiver extension;

a powered rail, extending along at least a portion of a length of a barrel of said weapon and connected to said power source, for providing a source of electrical power to a one or more power-consuming accessories which are mechanically and electrically attached to the powered rail; and

a power distribution system for electrically interconnecting said power source and said powered rail.

4. The Weapon Accessory Power Distribution System ofclaim 3 wherein said power source further comprises:

internal battery spring terminals which serve to engage one end of a plurality of replaceable battery cells and are electrically connected to said electrode terminals.

5. The Weapons Accessory Power Distribution System ofclaim 1 wherein said adjustable buttstock is collapsible and can be extended in various multiple intermediate positions.

6. The Weapons Accessory Power Distribution System ofclaim 1 further comprising:

electrical contacts mounted on said distal end of said receiver for mechanically and electrically engaging said pair of exposed electrode terminals mounted on an exterior surface of said housing.

7. A Weapon Accessory Power Distribution System for providing a supply of electrical power for use by at least one power-consuming accessory operatively associated with a weapon, said weapon power distribution system comprising:

a handguard, which extends along a length of a barrel of a weapon and which mechanically supports one or more power-consuming accessories;

a receiver extension attached at a distal end of a receiver of a weapon and containing a mechanical feature formed along a length thereof;

a power source mounted on said receiver extension by the interconnection of a mechanical feature on the power source with the mechanical feature of the receiver extension;

an adjustable buttstock containing an aperture formed along a length thereof which aperture encloses the receiver extension and the attached power source and which provides a slideable attachment of said adjustable buttstock to said receiver extension for positioning said adjustable buttstock at one of a plurality of predetermined positions on said receiver extension;

a powered rail, incorporated in said handguard and extending along at least a portion of a length of a barrel of said weapon and connected to said power source, for providing a source of electrical power to a one or more power-consuming accessories which are mechanically and electrically attached to the powered rail;

a power distribution system for electrically interconnecting said power source and said powered rail; and

a latch mounted on said receiver extension to lock said power source on said receiver extension.

8. The Weapons Accessory Power Distribution System ofclaim 1 wherein said power source mounts on said receiver extension independent of the adjustable buttstock which telescopes along the receiver extension.

9. A Weapon Accessory Power Distribution System for providing a supply of electrical power for use by at least one power-consuming accessory operatively associated with a weapon, said weapon power distribution system comprising:

a handguard, which extends along a length of a barrel of a weapon and which mechanically supports one or more power-consuming accessories;

a receiver extension attached at a distal end of a receiver of a weapon and containing a mechanical feature formed along a length thereof;

a power source mounted on said receiver extension by the interconnection of a mechanical feature on the power source with the mechanical feature of the receiver extension, comprising:

a battery compartment that comprises a substantially cylindrical housing with a spring loaded cover,

a pair of exposed electrode terminals mounted on an exterior surface of said battery compartment,

a plurality of replaceable battery cells housed in said battery compartment and electrically connected to said electrode terminals;

an adjustable buttstock containing an aperture formed along a length thereof which aperture encloses the receiver extension and the attached power source and which provides a slideable attachment of said adjustable buttstock to said receiver extension for positioning said adjustable buttstock at one of a plurality of predetermined positions on said receiver extension;

a powered rail, incorporated in said handguard and extending along at least a portion of a length of a barrel of said weapon and connected to said power source, for providing a source of electrical power to a one or more power-consuming accessories which are mechanically and electrically attached to the powered rail; and

a power distribution system for electrically interconnecting said power source and said powered rail.

10. The Weapons Accessory Power Distribution System ofclaim 9 wherein said battery compartment and said spring loaded cover form a watertight container for batteries loaded therein.

11. The Weapons Accessory Power Distribution System ofclaim 1 wherein said power source is slideably attached to said receiver extension.

12. The Weapons Accessory Power Distribution System ofclaim 3 wherein said adjustable buttstock is collapsible and can be extended in various multiple intermediate positions.

13. The Weapons Accessory Power Distribution System ofclaim 3 further comprising:

electrical contacts mounted on said distal end of said receiver for mechanically and electrically engaging said pair of exposed electrode terminals mounted on the exterior surface of said housing.

14. The Weapons Accessory Power Distribution System ofclaim 3 further comprising:

a latch mounted on said receiver extension to lock said power source on said receiver extension.

15. The Weapons Accessory Power Distribution System ofclaim 3 wherein said power source mounts on said receiver extension independent of the adjustable buttstock which telescopes along the receiver extension.

16. The Weapons Accessory Power Distribution System ofclaim 3 wherein said battery compartment and said spring loaded cover form a watertight container for batteries loaded therein.

17. A Weapon Accessory Power Distribution System for providing a supply of electrical power for use by one or more power-consuming accessories operatively associated with a weapon, comprising:

a handguard, which extends along a length of a barrel of a weapon and which mechanically supports one or more power-consuming accessories;

a receiver extension attached at a distal end of a receiver of a weapon and containing a mechanical feature formed along a length thereof;

an adjustable buttstock containing an aperture formed along a length thereof which aperture encloses the receiver extension and an attached power source and which provides a slideable attachment of said adjustable buttstock to said receiver extension for positioning said adjustable buttstock at one of a plurality of predetermined positions on said receiver extension and wherein said power source is slideably attached to said receiver extension;

a powered rail, extending along at least a portion of a length of a barrel of said weapon and connected to said power source, for providing a source of electrical power to a one or more power-consuming accessories which are mechanically and electrically attached to the powered rail; and

a power distribution system for electrically interconnecting said power source and said powered rail.

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